Ventilated seat cushion

ABSTRACT

A seat includes one or more cushions secured to a shell. The cushions include a 3D printed lattice of repeating cells. The cells may include nodes interconnected by branches. The nodes may be arranged in a cubic, parallelepiped, diamond, or other arrangement. The branches may extend directly between nodes or may be bent. The branches may extend from each node to an adjacent node that is closest to its point of attachment to the each node or the branches may be curved or bent to secure to a different adjacent node. The 3D printed lattice may include 3D printed barbs formed thereon that engage receptacles in the seat shell. The 3D printed lattice may be printed with a groove that engages a fastening structure on a cover or a separate fastening element. The cover may be a perforated sheet of material or fabric.

CROSS REFERENCE TO RELATED PATENT APPLICATION

The present disclosure is part of a divisional application of U.S.patent application Ser. No. 15/234,873, filed on Aug. 11, 2016, thecontent of which is incorporated by reference in its entirety.

BACKGROUND Field Of The Invention

This invention relates to cushions for a seat of a vehicle or otherapplications.

Background of the Invention

Automotive seats are typically made of molded foam pads wrapped witheither vinyl or leather outer cover. This type of construction may notoptimize air circulation between the occupant and the seat.

The systems and methods described herein provide an improved approach tothe design and manufacture of cushions for use in vehicle seat bottoms,backs, headrests, or for any other application where cushions may beused.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered limiting of its scope, the invention will be describedand explained with additional specificity and detail through use of theaccompanying drawings, in which:

FIG. 1A is perspective view of a vehicle seat;

FIG. 1B is a diagram of a seat shell having seat pads secured thereto inaccordance with an embodiment of the present invention;

FIGS. 2A to 2B are side cross-sectional views showing securement of acushion to a seat shell in accordance with an embodiment of the presentinvention;

FIG. 3 is a side cross-sectional view of a cushion including a latticestructure having a cover secured thereto in accordance with anembodiment of the present invention;

FIGS. 4A and 4B are side cross sectional views showing means forsecuring a cover to a cushion in accordance with an embodiment of thepresent invention;

FIG. 5 is a perspective view of a 3D printed cushion in accordance withan embodiment of the present invention;

FIGS. 6A to 6F are perspective views of cells for use in a latticestructure of a seat pad in accordance with an embodiment of the presentinvention.

DETAILED DESCRIPTION

Referring to FIGS. 1A and 1B, a typical vehicle seat 10 includes a seatbottom 12 and seat back 1 oriented at an angle relative to the seatbottom 12 as known in the art. As also known in the art, the seat bottom12 may be mounted to a base 16 that may include one or more motors foractuating the seat. One or more temperature modulating elements, e.g.heating and cooling elements may be embedded in the seat bottom 12and/or seat back 1 as known in the art.

A seat 10 in accordance with the embodiments disclosed herein mayinclude a seat bottom 12 having a plurality of cushions 18 defining aseating surface and lateral bolsters 20 extending upwardly and outwardlyfrom the seating surface at an angle. Likewise, the seat back mayinclude a plurality of cushions 22 defining a back support surface.Lateral bolsters 24 may extend forwardly and outwardly from the backsupport surface. In some embodiments, the cushions 18, 22 are formed ofa 3D (three-dimensionally) printed lattice according to any of theembodiments described below. The bolsters 20, 24 may be formed of aconventional open cell latex foam, or any other cushioning materialknown in the art. In other embodiments, the bolsters 20, 24 are alsoformed of a 3D printed lattice according to any of the embodimentsdescribed below.

As shown, the cushions 18 and bolsters 20 may mount to a base shell 26.The cushions 22 and bolsters 24 may mount to a back shell 28. The shells26, 28 may be formed of a rigid plastic, metal, composite (e.g.fiberglass or carbon fiber), or any other material of sufficientstructural rigidity.

Referring to FIGS. 2A and 2B, the cushions 18, 22 may secure to the baseshell 26 and back shell 28 by various means. For example, adhesives,ultrasonic welding, fasteners (screws, snap-in fasteners) or the likemay be used to secure the cushions 18, 22 to the base shell 26 and backshell 28.

Referring to FIG. 2A, in some embodiments, the cushions 18, 22 maydefine a projection 30 that seats within a receptacle 32 formed in thebase shell 26 and back shell 28. The receptacle 32 may facilitatealignment and placement of the cushions 28, 22. A surface 34 on thecushions 18, 22 may engage a corresponding surface 36 on the shell 26,28. For example, surface 34 may bear one part of a hook-and-loopfastening system, e.g. VELCRO, and the surface 36 may bear the otherpart of the hook-and-loop fastening system. Alternatively, the surfaces34, 36 may secure to one another by means of adhesive, ultrasonicwelding, or a fastener.

Referring to FIG. 2B, in an alternative embodiment, the cushions 18, 22are 3D printed having posts 38 protruding from a surface thereof. Theposts 38 may include a tapered end 40 and shoulders 42 extendinginwardly from the perimeter of the tapered end 40 to the posts 38. Theshells 26, 28 may define receptacles 44. The receptacles 44 may besimple through-holes or may have corresponding features to the taperedend 40, shoulders 42, and post 38. For example, each receptacle 44 mayinclude a cylindrical portion 46, a shoulder 48 radiating outwardly fromthe cylindrical portion 46, and a conical volume 50. Accordingly, asshown in FIG. 2B, when engaged the posts 38 are positioned in thecylindrical portion 46, the shoulder 40 engages the shoulder 48, and thetapered end 40 is positioned within the conical volume 50.

In some embodiments, the posts 38 and tapered end 40 may be rectangular,i.e. a projection of the illustrating cross section. Accordingly, thereceptacles 44 may have a corresponding constant cross sectionperpendicular to the page.

Referring to FIG. 3, a cushion 18, 22 may include a 3D printed lattice60 having a cover 62 extending over surfaces of the lattice 60 thatsupport a seated person when the cushion 18, 22 is mounted to itscorresponding shell 26, 28. The cover 62 is preferably formed of abreathable material such as perforated leather, imitation leather, orother plastic material. The cover 62 may be formed of a breathablefabric. Various means may be used to secure the cover 62 to the 3Dprinted lattice 60. For example, an adhesive may be positioned betweenthe mating surfaces of the cover 62 and 3D printed lattice 60.Alternatively, the cover may be sewn to the 3D printed lattice 60 orsecured thereto by means of fasteners such as rivets.

Referring to FIG. 4A, in some embodiments, the cover 62 secures to the3D printed lattice 60 along its edge. For example, the 3D printedlattice 60 may be manufactured with a groove 64 undercutting a surface66 thereof. The groove 64 may extend completely around the cushion 18,22. The cover 62 may define a hook 68 with an end portion 70 that seatswithin the groove 64. In some embodiments, the hook 68 and/or endportion 70 are formed of a rigid material, such as rigid yet flexiblepolymer that is different from the breathable material forming the restof the cover 62. In some embodiments, an elastic is sewn or otherwisesecured around an edge of the cover 62 such that the elastic seatswithin the groove 64 in order to retain the cover 62 in engagement withthe 3D printed lattice 60.

Referring to FIG. 4B, in an alternative embodiment, a clip 72 seatswithin the groove 64 and grasps the cover 62 between itself and thesurface 66 thereby retaining the cover 62. The clip 72 may include anelongate member having the illustrated cross-section such that the clip72 secures the cover 62 along some or all of the perimeter of thecushion 18, 22.

Referring to FIG. 5, in some embodiments, the 3D printed lattice 60 mayhave the illustrated configuration. 3D printing the cushions 18, 22 mayinclude any additive manufacturing process known in the art. Forexample, the cushions 18, 22 may be 3D printed out of a photo-polymer,thermo-polymer, or any other polymer using any additive manufacturingtechnique known in the art.

As shown, the 3D printed lattice 60 may include an upper sheet 80 and alower sheet 82. The sheets 80, 82 may be planar sheets of materialhaving apertures 84 extending therethrough to facilitate ventilation. Anarray of cells 86 are positioned between the sheets 80, 82 according toregular repeating pattern. The apertures 84 may have a repeating patternhaving identical pitch to that of the repeating pattern of the cells 86.Each cell includes at least one node 88 and a plurality of branches 90extending from the node 88 to an adjacent node 88. The cells 86 may havemultiple configurations and may be selected to provide desiredproperties for the 3D printed lattice 60, e.g. firmness, ventilation,etc.

FIGS. 6A to 6F illustrate example cells 86 that may be used in the 3Dprinted lattice 60. Referring to FIG. 6A, in one embodiment the cells 86include nodes 88 arranged at the vertices of a diamond and the branches90 positioned along the edges of the diamond. In the illustratedembodiment, a pair of nodes 88 positioned on opposite corners of thediamond are aligned along a vertical direction 92, which correspondsgenerally (e.g. within 15 degrees) of a direction of compression of the3D printed lattice 60 when in use. As shown in the embodiment of FIG.6A, each node 88 has eight branches 90 protruding therefrom.

Referring to FIG. 6B, in another embodiment, the nodes 88 include firstnodes 88A arranged in a cubic arrangement aligned with the verticaldirection 92, horizontal direction 94, and longitudinal direction 96,the directions 92, 94, 96 all being mutually orthogonal. The directions92, 94, 96 are called out to facilitate definition of the cells 86described herein and do not necessarily correspond to the actualvertical, horizontal, and longitudinal directions of a system in whichthe cells 86 are used.

As is apparent in FIG. 6B, the branches 90 include branches 90A thatextend between nodes 88A that are aligned along vertical direction 92and along the horizontal direction 94. Note that in the illustratedembodiment, the branches 90A do not extend between nodes 88A that arealigned along the longitudinal direction 96.

The nodes 88 further include nodes 88B that are positioned at the centerof cubes defined by the nodes 88A. The branches 90 further includebranches 90B that extend from each node 88B to adjacent nodes 88A, i.e.that radiate diagonally outwardly from the center of the cube defined bythe nodes 88A to the corners of the cube.

In the illustrated embodiment, the branches 90 further include branches90C that extend between nodes 88B that are aligned along the verticaldirection 92. Accordingly, in the illustrated embodiment each node 88Ahas 12 branches 90A, 90B connected thereto and each node 88B has 10branches 90B, 90C connected thereto.

Referring to FIG. 6C, in another embodiment, the nodes 88 are arrangedon a parallelepiped that may be cubic nor non-cubic. The edges of theparallelepiped may be at a non-zero and non-perpendicular angle withrespect to some or all of the vertical, horizontal, and longitudinaldirections 92, 94, 96.

Referring 6D, in another embodiment, the nodes 88 are arranged in acubic arrangement with edges aligned with the vertical, horizontal, andlongitudinal directions 92, 94, 96. In this embodiment, the branches 90extending between nodes are bent such that rings 100 are defined by thebranches 90. The rings 100 may be oriented at a non-zero andnon-perpendicular angle with respect to the vertical, horizontal, andlongitudinal directions 92, 94, 96. As is also apparent, the rings 100may be arranged at non-zero angles with respect to one another accordingto a repeated pattern.

Referring to FIG. 6E, in another embodiment, the nodes 88 are arrangedin a non-cubic and non-parallelepiped arrangement. The nodes 88 includeonly four branches 90 protruding therefrom.

Referring to FIG. 6F, in another embodiment, the nodes 88 of a cell 86are arranged on the vertices of a diamond, such as a diamond having theorientation shown in FIG. 6A. However, each node 88 is “twisted”relative to some or all of the directions 92, 94, 96. In particular,each branch 90 does not follow a direct path to an adjacent node 88 fromthe point of attachment to the each node 88, but rather is bent andcurve around each node 88 to connect to an adjacent node 88. The amountof twist and the shape of the branches 90 may vary in order to alter theproperties of the 3D printed lattice 60 including the cells 86. Inparticular, note that the embodiment of 6F converts linear compressioninto torsional deformation of the branches 90, rather than linearstretching or compression of the branches 90.

Various modifications of the cells 86 may be performed to adjust theproperties of the 3D printed lattice 60 to achieve desired mechanicalproperties. In addition, the size of the cells 86 may be modified toaffect the desired mechanical properties. The cells 86 shown above mayhave a size along any of the directions 92, 94, 96 of between 5 and 30mm. The branches 90 may have a diameter of 1 and 5 mm.

In some embodiments, the size of the cells 86 may also be varied withinthe same cushion 18, 22 or from one cushion 18, 22 to an adjacentcushion in order to provide varying firmnesses. The lattice pattern usedwithin the same cushion 18, 22 or a set of cushions 18, 22 used for aseat may also vary in order to provide varying and/or tailoredfirmnesses. For example, arbitrary nodes or solid or perforated planesmay be introduced at the boundaries between cells 86 having a differentsize or different pattern, the branches 90 of the cells 86 may thenattach to the arbitrary nodes or to opposing sides of the plane.

In the above disclosure, reference has been made to the accompanyingdrawings, which form a part hereof, and in which is shown by way ofillustration specific implementations in which the disclosure may bepracticed. It is understood that other implementations may be utilizedand structural changes may be made without departing from the scope ofthe present disclosure. References in the specification to “oneembodiment,” “an embodiment,” “an example embodiment,” etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described.

While various embodiments of the present disclosure have been describedabove, it should be understood that they have been presented by way ofexample only, and not limitation. It will be apparent to persons skilledin the relevant art that various changes in form and detail can be madetherein without departing from the spirit and scope of the disclosure.Thus, the breadth and scope of the present disclosure should not belimited by any of the above-described exemplary embodiments, but shouldbe defined only in accordance with the following claims and theirequivalents. The foregoing description has been presented for thepurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure to the precise form disclosed.Many modifications and variations are possible in light of the aboveteaching. Further, it should be noted that any or all of theaforementioned alternate implementations may be used in any combinationdesired to form additional hybrid implementations of the disclosure.

The invention claimed is:
 1. A seat comprising: a seat shell; one ormore polymer pads fastened to the seat shell, the one or more polymerpads each including a three-dimensional (3D) lattice structure includinga plurality of identical repeated cells; and a porous sheet of materialfastened over the one or more polymer pads; wherein each cell of therepeated cells includes a node and a plurality of branches eachconnecting the node to other nodes of the lattice structure.
 2. The seatof claim 1, wherein the identical repeated cells each have a height,width, and depth that are between 5 and 30 mm.
 3. The seat of claim 1,wherein the nodes of the repeated cells are arranged in at least one ofa cuboid relationship and a parallelepiped relationship.
 4. The seat ofclaim 1, wherein the plurality of branches are at least one of (a) bentbetween points of attachments to the nodes of the repeated cells and (b)do not interconnect closest nodes of the repeated cells.
 5. The seat ofclaim 1, wherein each cell of the repeated cells includes between 6 and12 branches connected thereto.
 6. The seat of claim 1, wherein the oneor more polymer pads each comprise one or more barb structuresmonolithically formed with the one more polymer pads; and wherein theone or more polymer pads are fastened to the seat shell by engagement ofthe one or more barb structures with one or more apertures defined bythe seat shell.
 7. The seat of claim 1, wherein: each pad of the one ormore polymer pads comprises a 3D printed indentation around a lower edgeof the each pad, the seat further comprising elastic material secured toa perimeter of the porous sheet of material and seated within the 3Dprinted indentation.
 8. The seat of claim 1, wherein: each pad of theone or more polymer pads comprises a 3D printed indentation around alower edge of the each pad, the seat further comprising a hooked portionsecured to a perimeter of the porous sheet of material and seated withinthe 3D printed indentation.
 9. The seat of claim 1, wherein: each pad ofthe one or more polymer pads comprises a 3D printed indentation around alower edge of the each pad, the seat further comprising a clip seatedwithin the 3D printed indentation and securing a perimeter of the poroussheet of material to the each pad.